Acid dyeing for tertiary aminated polyamide,polyolefin and polyamide blends and disperse dyeing of said polyolefin and polyester blends

ABSTRACT

A UNION DYED, SOLID COLORED, TUFTED CARPETING, UNIFORMLY SHADED IN BOTH THE FACE YARNS AND IN THE BACKING MATERIAL, COMPRISES AS THE BACKING MATERIAL WOVEN RIBBONS OF A COMPOSITION COMPRISING A POLYOLEFIN BLENDED WITH A BASIC POLYAMIDE DYE SITE ADDITIVE, SAID ADDITIVE CONSISTING OF A MINOR INCORPORATED AMOUNT OF A POLYAMIDE RESIN BASED ON A LINEAR ALIPHATIC DICARBOXYLIC ACID AND POLYAMINE CONTAINING TWO PRIMARY OR SECONDARY AMINE GROUPS AND AT LEAST ONE TERTIARY AMINE GROUP.

'P 12, 1972 G. HORNING 3,690,811

K. ACID DYEING FOR TERTIARY AMINATED POLYAMIDE, POLYOLEFIN AND POLYAMIDE BLENDS AND DISPERSE DYEING OF SAID POLYOLEFIN AND POLYESTER BLENDS Filed June 1, 1970 Kermit 6. Horn/0g I N VEN'IOR.

AITTORNE) 3,690,811 ACID DYEING FOR TERTIARY AMINATED POLY. AMIDE, POLYOLEFIN AND POLYAli HDE BLENDS AND DISPERSE DYEING OF SAID POLYOLEFIN AND POLYESTER BLENDS Kermit G. Homing, Waynesboro, Va., assignor to Thiokol Chemical Corporation, Bristol, Pa. Filed June 1, 1970, Ser. No. 42,357 Int. Cl. D061: 3/82 US. Cl. 8-21 B 14 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION Field of the invention This invention relates to a dyed tufted carpet in which both the carpet backing and the tufted face yarns are synthetic materials and are dyed to the same shade of the same color. Particularly, the invention relates to a synthetic fabric comprising a piece dyeable polypropylenepolyamide composition backing which dyes to a similar shade, described in the dyeing art as a union shade, in competition with tufted face yarns of nylon or polyester material, and wherein both the backing and the face yarns are dyed with the same acid or disperse dye in a single dye bath in a single dyeing operation.

Description of the prior art The use of polypropylene filaments in ribbon or tape form interwoven to make a fabric which can be used as a backing material into which face yarns can be tufted to make a tufted carpet has become a widely practiced art. Tufted pile fabric comprising such a flat woven synthetic plastic backing is taught, for example, by T. M.

Rhodes, US. Pat. 3,110,905. The synthetic materials used in making the backing and the face yarns are normally colorless or light beige colored materials which in themselves are unattractive for most fabric uses. Accordingly, dyeing of the materials ordinarily must be done to manufacture an attractive fabric. For example, the backing can be prepared from a ribbon filament which has been dyed by incorporation of a dye in the melted plastic material from which the filament is extruded. Also, the backing may be dyed after it has been woven into a fabric. The face yarn similarly may be dyed in its prefilamented or fibered form or after it has been formed into the yarn filament or fibered and twisted into a face yarn.

When a carpet manufacturer wishes to manufacture a solid colored tufted carpet using the synthetic carpet backing material, and a synthetic face yarn, he thus has several choices as to the colors of his starting materials. If he uses a previously dyed backing of a particular color and shade, he must then obtain a colored faceyarn which United States Patent will match the color and shade of the backing. This selection is particularly critical if he is concerned about the backing showing through the face yarn. This concern in fact becomes a problem when tufted carpeting is applied over curved surfaces having sharp bends, such as the nosings on stairs. In such uses, the tufted carpeting is bent sharply, and even when it is densely tufted, the backing may show through the tufts of the yarn. Because the carpet tufter usually will be obtaining his backing material from one supplier and his face yarns from a different supplier, he may encounter considerable difliculty in obtaining a close match as to shade between the color of the face yarn and the color of the backing, particularly when he is tufting a carpet of a bright solid color, for example, a bright orange. Some carpet manufacturers are integrated in their operations to dye the carpet after it has been manufactured, and prefer to use an undyed face yarn in order to avoid stocking a large variety of colors of yarn, or for some other reason of economy. In the latter situation, the carpet manufacturer must be able to dye the face yarn to any desired color and shade. However, he also, in such case, may desire that the face yarn assume the same color and shade as the backing, so that the tufting need not be as dense as would be required to hide or minimize show-through when the carpeting is bent as discussed above. If both the carpet backing and the face yarn are used in an undyed condition in making the carpet and then are dyed simultaneously, it has been found that the face yarn and the backing material often do not dye to the same shade. This result may be due in part to the difference in sizes of the filaments or fibers of the face yarn as compared to the filaments of the backing, and the consequent optical effects which result, as well as in the difference in dye receptivities of a heavy thick ribbon and a thin fiber. For example, the backing for the tufted carpet is woven from large ribbon monofilaments of 500 to 100.0 denier, whereas the face yarn may be formed of fine fibers of about 15 denier each.

Face yarns are usually derived from synthetic polymers, for example, polyamides, such as nylon, or polyesters, which have high dye afiinity and which, accordingly, can be dyed readily to a wide variety of shades of color as well as to a wide variety of colors. On the other hand polypropylene, which is used mostly as a backing material and not as a face yarn, does not readily accept an organic dye. In order to overcome this disadvantage of polypropylene as a dyeable fabric material, a large variety of modified polypropylenes have been developed which makes the polypropylene composition thus formed a dyeable material. However, a modified polypropylene, while it accepts a dye, may not at the same time accept the dye in such a way and amount that it will assume the same shade of color as that of the face yarn which is tufted into the backing fabric, when the two are dyed simultaneously, in the same dye bath. The present invention overcomes this problem.

SUMMARY OF THE INVENTION The present invention is directed to a dyed synthetic material fabric, particularly carpeting, in which the backing material comprises a polyolefin composition containing a basic polyamide dye site additive which creates in the backing dyeability characteristics which cause the backing material when union dyed, after being tufted with a polyamide or polyester face yarn, to assume substantially the same shade of color as is assumed by the face yarn when the carpet fabric is dyed in a single bath containing the same dye for both the backing and the face yarns. The term union dyed as used throughout the disclosure of this invention is intended to have the usual definition for goods dyed by a union dyeing process, Le. a process which is a one-bath process as a result of which the same color or shade can be imparted to two or more textile fibers or yarns in the same piece or material.

Particularly, in the invention, the polyolefin composition used in preparing the filament ribbon from which the carpet backing is woven comprises from about 80 to 99.5% by weight of a stereoregular or isotactic polyolefin and 0.5 to by weight of a basic polyamide comprising the reaction product of an aliphatic dicarboxylic acid or derivative thereof and a polyamine containing not more than two primary amino groups and one or more tertiary amino groups, and wherein said basic polyamide is present in an amount suflicient to provide 0.1 to 1.0% by weight of basic nitrogen in the composition and said basic polyamide has a crystallite melting point in the range 50250 C. Preferably, the polyamide is one derived by reacting azelaic acid, methyl bis- (3-aminopropyl) amine and hexamethylenediamine. Also, preferably, the polyolefin is selected from linear polyethylene, stereoregular poly-(4-methylpentene-1) and isotactic polypropylene.

BRIEF DESCRIPTION OF THE DRAWING A union dyed tufted carpet made according to the invention is illustrated in FIG. 1 in comparison to a nonunion dyed piece of tufted carpet which is illustrated in FIG. 2. In FIG. 1, carpet 1 is shown to have both its woven backing 3 and 3a dyed substantially to the same shade as the face yarn 6 which has been tufted into the backing. The area around 3a has been exposed by pulling out tufts of the material to illustrate the sameness of shade of the backing with the shade of color of the face yarn. FIG. 1 thus graphically illustrates a union dyed product of the invention.

In contrast to FIG. 1, FIG. 2 shows that the woven backing 4 and 4a has a different shade of coloring than does the face yarn 5. The area around 4a has been exposed by pulling out tufts. The product of FIG. 1 is further distinguished over the product illustrated in FIG. 2 in that the woven backing 3a has been woven from a polyolefin-polyamide composition according to the invention, whereas the backing 4a has been woven from 100% isotactic polypropylene filament ribbon.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The polyolefin compositions used in practicing the invention are known compositions and are taught, for example, in US. Patent 3,433,853. The basic polyamides and their method of use in preparing the polyolefin compositions used in practicing the present invention also are taught in U.S. 3,433,853 and are incorporated by reference into the present invention as materials useful in the practice in the present invention. The basic polyamides, according to the invention, are condensation polymers which are substantially insoluble in water and which have a crystallite melting point (measured using a Fisher- Johns melting point apparatus) of from about 50 C. to about 250 C. If the crystallite melting point of the basic polymer exceeds about 250 C., the polyolefin composition containing it becomes less easily shaped into uniform articles. These polymers, moreover, do not undergo branching and crosslinking during extrusion of the polyolefin compositions and do not degrade during processing.

Preparation of a typical basic polyamide useful for practice of the present invention is described in Example 1, which follows, and preparation of a typical polypropylene composition comprising a basic polyamide is described in Example 2, which also follows.

Example l.--A basic polyamide containing tertiary amine groups is prepared from the following ingredients in the indicated proportions:

Moles Azelaic acid 1.50 Hexamethylenediamine (60% aqueous) 0.7875 N,'N-bis-(3-aminopropyl)methyl amine 0.7875

The azelaic acid is placed into a 500-ml. resin kettle equipped with a stainless steel stirrer, take-off condenser, nitrogen inlet, thermometer and addition funnel. The amines are added conjugately to the acid melt (115 C.) with stirring in an atmosphere of nitrogen. The amine addition should take from 20 to 30 minutes. When the amines have been added, the temperature is raised to 175 C. for 2 hours. Finally, a vacuum (50 mm. Hg) is applied for 30 minutes. The product is quickly poured into an aluminum pan and allowed to cool in a desiccator over CaSO in a nitrogen atmosphere. The resulting product is white in color and has a melting point range of 163 C.-1'67 C. and a relative viscosity (2% solution in formic acid at 25 C.) of 1.64.

A basic polyamide containing secondary amine groups is similarly prepared from the following ingredients:

Moles Sebacic acid 1.50 Hexamethylenediamine (60% aqueous) 0.7875 Diethylene triamine 0.7875

The product has a viscosity (2% solution in 90% formic acid at 25 C.) of 1.8 to 1.9.

'Example 2.Polyamides, prepared as above described, are mixed with isotactic polypropylene (polyamide, 7.5 parts; polypropylene, 92.5 parts) and each mixture then extruded at temperatures from about ZOO-210 C. through a 325 mesh screen and die to form strands which are then fed through cooling water and a cutter to form pellets. The pellets are then used as a textileforming substance to form filaments in a known way through filament forming dies from a bath of the melted polymer composition. The pelleting operation may, if desired, be omitted and filaments formed directly from the molten blend by use of suitable dies.

In practicing the present invention, a polyolefin-polyamide composition such as that described in Example 2 is extruded and stretch oriented by known means into a ribbon form of filament mils wide and of 1080 denier. The filaments are woven into a primary backing material substantially in the manner described in the Rhodes patent. The fabric so formed is manufactured into carpeting by tufting the backing with, for example, 3700 denier nylon 66 (hexamethylene adipamide) as sold by Du Pont under the trademark Antron Type 846 nylon, using, for example, ten stitches per inch and 6.5 rows per inch of the nylon, forming a pile height of of an inch. The carpet fabric so formed is preferably beck dyed in rope form by the following general procedure.

Preliminary to the dyeing of the carpeting, the carpet fabric is pre-scoured in a bath containing about 0.5% o.w.g. (on weight of goods) of a non-ionic detergent and about 0.5% o.w.g. of sodium carbonate. Any suitable non-ionic detergent may be used, for example. Triton X-lOO, an isooctyl phenyl polyethoxy ethanol surfactant. The scouring is carried out at a temperature of F. for about 15 to 20 minutes to remove materials used in finishing the yarn, e.g. lubricants, dust, grime, and so forth, which may be present on the tufted carpeting. The pre-scoured carpeting is then thoroughly rinsed with clear water.

An acid dye bath (used only with nylon face fabric) is prepared by mixing the acid dye to be used with water to obtain a smooth, uniform paste, or by dispersing the acid dye in about five times its weight of surfactant, e.g. a 10% alkyl aryl polyether surfactant sold under the trademark Nacconol SL. The amount of dye used will usually range from about 0.5 to 8% o.w.g., with about 1 to 2% o.w.g. preferred. In either case, the dye mixture obtained is further diluted with bath water equal to from 20 to 100 times the weight of a fabric to be dyed. The ratio of bath liquor to the carpet material in the bath preferably should be about 40 to 1 by weight ratio. Nylonfaced carpet then is placed in a beck apparatus in rope form in about 20 to 100 parts o.w.g. of water. Before mixing the dye concentrate in the water used for the main body of the bath, the bath water is heated to an initial bath temperature of about 100 F. The pH of I the bath is adjusted and maintained between 6.5 and 7.5 with a buffer such as monosodium phosphate, NaH PO The acid dyestuff, preferably one of the dyes selected from those listed by Color Index Number in Table 2, is dissolved in the bath to make a concentration ofdyestuif of 2.0% o.w.g. The temperature of the bath is then raised to about 160 to 170 F. Acidity of the bath is adjusted to a pH of 3.0 to 3.5 with formic acid or an acid forming salt or other organic acid while bringing the bath to a boil at the rates of about 2 to 3 degrees per minute. The dyeing process is carried on for about 1 /2 hours at a temperature of about 205 to 210 F. The bath is then drawn 01f and the dyed carpeting is then preferably post-scoured with a scouring bath containing from 0.01 to 5% of a detergent, preferably 0.5% Triton X-l00, adjusted with sodium carbonate to a pH 9.5 to 10. The scouring is carried out at 150 F. for about 20 minutes. A union dyed nylon-faced carpet is thus provided.

In practicing the present invention, it has been found that, whereas nylon face yarn may be dyed either by means of an acid dye or a disperse dye, a polyester face yarn must be dyed with a disperse dye in order to get a union shade of color in both the face yarn and the polypropylene-polyamide composition backing. When a disperse dyestuif is to be used, the dyeing procedure is somewhat different from that used in using an acid dyestulf. In either case, the scouring treatments are the same. A bath for dyeing with a disperse dye is prepared substantially as described for the acid bath. Sulficient bath water is provided to establish a ratio of about 40 parts by weight of liquid to one part by weight of carpeting. Polyester-faced carpet is placed in the bath water, preferably in a beck dyeing machineand in rope form. Then 1% o.w.g. of monosodium phosphate is added as a buffer. The bath temperature is raised to about 160 'F. To the bath then is added 5% o.w.g. of a carrier, Carolid 3 F (Tanatex Corp.). The bath is then adjusted with acetic acid (1% o.w.g.) to a'pH of 5.5 to 6.0. The disperse dyestutf which is to be used to dye the carpet fabric is then introduced into the bathas a concentrate in hot water. The pH is then re-checked and, if necessary, adjusted to the 5.5 to 6.0 range. The temperature of the bath is then raised to the boiling point at a rate of about 3 per minute. The goods are then dyed at the boil for about 60 minutes, or until a uniform depth, 'i.e. union shade, of color is obtained both in the face yarn'and the backing. The dye bath solution is then drained off and the union dyed carpeting is rinsed in hot water at about 160 F., or higher, to remove the residual dye and carrier. The dyed tufted carpeting is given afinal rinse in cool water and then dried. a

In carrying out the acid dye bath process, it has been found advantageous to start the acid dye cycle at a relatively higher pH in. the range of 5.5 to 7.0, and then to lower the pH either incrementally during the dye cycle or, preferably, all at one time after the-boiling point has been reached, to a pH of 3.5 or less. This procedure promotes a deeper shade in both the backing and the face yarn and helps to provide a union shade without as much likelihood of obtaining a streaked face yarn as is likely when the dyeing is carried out at a low pH for the entire dye cycle. Disperse dyestuffs which have been found advantageous for producing solid union dyed shades of color in tufted carpeting made and dyed according to the invention are listed in Table 1. It is to be understood that this list does not include all disperse dyes which may be useful for the practice of the invention, but it is representative of dyes which has been found to provide a union shade in both the face yarn and the backing When the invention is practiced. Acid dyestuffs which may be used in practicing the invention are listed in Table 2.

. The amount of disperse dyestutf which will be required in a particular dyeing situation may range from about 0.25to 3.0% o.w.g. A bath containing 0.5% o.w.g. is especially preferred.

The nylon face yarn of the carpeting preferably is made of nylon 66, a polyamide fiber-forming substance whose chemical composition is hexamethylene adipamide. For acid dyeing, nylon Type 846, sold under the trademark Du Pont, is especially preferred for acid dyeing processes. However, any long chain synthetic polyamide havin racurring amide groups as an integral part of the polymer chain may advantageously be used as the face yarn in the union dyed carpeting of the present invention. Suitable nylon fibers in yarn form for use in the practice of the invention may be selected from those described in Guidebook to Man- Made Textile Fibers and Textured Yarns of the World, Adeline A. Dembeck, The United Piece Dye Works, New York, N.Y., 3rd edition, pages 136-158, incorporated herein by reference.

The polyester face yarn of the carpeting may be made of a fiber of any long chain synthetic polymer composed of at least by weight of an ester of a dihydric alcohol and terephthalic acid Suitable polyesters for use in practice of the invention also may be selected from the Guidebook, supra, pages 172-186 of which are also incorporated herein by reference.

A preferred polyester fiber-forming substance is polyethylene terephthalate fiber, although others may be employed, more specifically those in which the recurring unit in the polyester chain is the diacyl aromatic radical from terephthalic acid, isophthalic acid, S-t-butylisophthalate, or naphthalene dicarboxylic acids, such as naphthalene- 2,6- and naphthalene-2,7-dicarboxylic acids.

The product and process of the present invention are surprising in view of the teachings of US. Patent 3,493,- 316. The patent teaches that when an upholstery fabric was prepared by weaving together five or six different fabric materials, and the composite fabric then is dyed in a dye bath containing a mixture of dispersed and acid dyes, each of the fabric materials assumes a different color. Specifically, the nylon 6 fabric, for example, dyed to a bright red, whereas a mixture of a 30% polyester-70% polyamide blend dyed to a bright orange, a polyethylene .terephthalate polyester dyed to a light tan, and a polyacrylonitrile, Orlon 42, dyed to a white, cellulose acetate dyed to a light orange, and silk dyed to a brown. Also, the patent teaches that a four component fabric prepared from nylon 66, nylon 6, 30% polyester-70% polyamide, and 40% polyester-60% polyamide was dyed with disperse dye Blue 3 in a single dye bath at 206 F.; the dyed fabric exhibited four different shades of the same color. Therefore, at the time the present invention was made, it was unexpected that a carpet backing made of polypropylene-polyamide composition containing 0.5 to 20% of a basic polyamide in blended form and tufted with a polyamide face yarn could be dyed in a union bath to a union dye shade in a single dye bath in a single dyeing operation. It was still less expected that the polypropylene-polyamide composition backing when tufted with a polyester face yarn could be dyed to a union dyed shade in a single dyeing with the same dye in the same dye bath.

The invention is further illustrated in the following examples:

Example 3.An acid dyeable polyolefin-polyamide composition prepared as described in Examples 1 and 2 above, and as further described in US. Patent 3,433,853, supra, was extruded into 500 denier XR ribbon and 1100 denier XR ribbon. The ribbon was woven into a closed weave fabric and tufted with Du Pont Antron Type 846 regular dyeing carpet nylon 66 (hexamethylene adipamide). The tufted carpet was scoured as discussed above and acid dyed in a mixture of acid dyes in accordance with the general procedure also discussed above. The acid dyestuffs used consisted of 1.65% Merpacyl Yellow 4 G, 0.05% Merpacyl Blue 2 GA, and 0.18% Nylomene Red B3BS, all percentages being based on the weight of the carpet material. The bath was prepared in a heck apparatus using 1% o.w.g. Alkanol ND (Du Pont) as a surfactant and 2% o.w.g. of monosodium phosphate as a buffer. The bath contained about 40 parts water per one part of carpet by weight. The carpeting was placed in the heck in rope form. The temperature of the bath was raised to the boiling point at about 3 per minute. The pH of the bath at this point was determined to be about 5.5 to 6.0. After 15 minutes at a boil, the bath was adjusted to a pH of 4.0 with formic acid. After another 15 minutes of boiling, the bath was adjusted to 3.5. The carpeting material then was dyed at the boil for 15 minutes of additional time. The bath water was then dropped and the dyed carpet was rinsed with water at 160 F. until clear. The carpet was then dried. The dyed tufted carpet was found to have the face yarn dyed to a uniform gold shade with the backing dyed to a satisfactory union gold shade.

Example 4.A woven fabric was prepared as in Example 3 and was then tufted with a regular dyeing spun polyester carpet yarn. A bath for beck dyeing of the tufted carpet with a disperse dyestutf was prepared using 40 parts water per one part of carpet by weight. The carpet was placed in the beck in rope form. The bath temperature was set at 100 F. Synthropol PWS (1% o.w.g.) (ethylene oxide condensate, nonionic surfactant) was added. A mixture of disperse dyestuffs was prepared in water solution. The mixture consisted of 0.14% Calcosyn Blue RP, 0.26% Latyl Orange 3 R, and 0.80% Setacyl Yellow P-GSL. The dyestutf mixture was added to the bath and the bath stirred until the dyestufif had been thoroughly dispersed. The temperature of the bath was then raised to 170 F. Then, 10% o.w.g. of Carolid 3 F carrier (chlorinated phenolic) (Tanatex Corporation) was added. The temperature was raised to the boiling point of the bath, and the carpeting was dyed at the boil for 45 minutes. The bath was then dropped and the dyed carpeting was rinsed and dried in the usual manner. The face yarn of the tufted carpet was found to be dyed to a uniform gold shade and the backing was dyed to a satisfactory union dye gold shade.

Examples 5-30.--Fabrics prepared as in Example 3 and tufted with a regular dyeing polyester fiber face yarn were used to make test pieces of tufted fabric which were laboratory dyed by the disperse dye dyeing procedure of Example 4. The disperse dyestuffs which were used and the amounts thereof, as well as the color rating which were determined, are shown in Table 1, Examples 530.

Examples 3135.-Fabrics were prepared as described in Example 3 and tufted with Du Pont Antron Type 846 nylon 66 face yarn. The carpet fabrics so prepared were dyed with a disperse dye. Each fabric was first pre-scoured with a water solution containing 0.5% o.w.g. of a nonionic detergent, Triton X-l00, and 1% o.w.g. of sodium carbonate, at 152 to 160 F. for 20 minutes to remove finish, lubricant, dust, and other contaminants. A dye bath was then prepared in a beck apparatus using 40 parts liquid to one part by weight of the carpet fabric. The

fabric was placed in the beck in rope form. The bath was heated to F. and 1% o.w.g. of a detergent, Merpol DA (ethylene oxide condensate, Du Pont) and 1% o.w.g. of trisodiumpyrophosphate were added. A disperse dyestuff selected from those shown in Table 1, Examples 31-35, was used to make a dye concentrate. The dye concentrate was added to the dyestulf in the amount of 0.5 o.w.g. The bath temperature was raised to about 205 to 200 F. at the rate of about 3 per minute. The dyeing operation was carried on for about 60 minutes. The bath was then drained off and the dyed carpet fabric was rinsed and the carpeting dried. The results obtained are shown in Table 1 under the heading Color Rating. Each dyed sample was at or near a union dye shade. The term near union shade is intended to mean that the shade of the backing and face yarn in each case were close enough to make the fabric acceptable for carpeting for home and office use.

Examples 36-46.Fabric prepared as described in Example 3 and tufted with Du Pont Antron Type 846 regular dyeing carpet nylon 66 was acid dyed using acid dyestuffs. The fabric was pre-scoured with a water solution containing 0.5% non-ionic detergent and 0.5% of sodium carbonate in the form of soda ash. Triton X-l00 was used as the detergent. A dye bath was prepared using 40 parts liquid per one part by weight of fabric. The tufted fabric was placed in a beck in rope form. The bath was set at 100 F. and 1% o.w.g. of Alkanol ND and 2% o.w.g. of monosodium phosphate were added. An acid dyestulf selected from the dyestuffs shown in Table 2 was added to the bath in about 2% o.w.g. The temperature of the bath was raised to a boil at the rate of 2 to 3 per minute. As the fabric was being dyed, the pH was adjusted to the range of 3.0 to 3.5 with formic acid. Dyeing was carried out at a temperature of about 205 to 210 F. over a 1 /2 hour period. The bath was then dropped and the dyed fabric was rinsed. The results obtained are shown in Table 2 under the heading Color Rating. It is shown that a union shade or near union shade was obtained in each dyeing.

Example 47.A tufted carpet prepared as described in Examples 36-46 was dyed in the manner described in Examples 36-46 using a mixture of dyestuffs comprising or consisting of 0.14% of Calcosyn Blue RP (Disperse Blue 116), 0.26% Latyl Orange 3 R (Disperse Orange 21), and 0.80% Setacyl Yellow P-GSL (Disperse Yellow 50). The dyed tufted carpet was found to have the nylon 66 face yarn dyed a uniform gold shade and the backing dyed to a union shade of gold.

While the invention has been described in relation to a union dyed tufted carpet fabric, it will be obvious to those skilled in the art that the invention can be practiced to union dye fabrics prepared for other use or constructed in other ways than by tufting a face yarn into a woven backing. For example, a woven fabric may be made by interweaving a polyester yarn or a polyamide yarn with a yarn or with ribbons or filaments of the polyolefin-polyamide composition used to practice the present invention, and then dyed to a union shade with an acid or disperse dye according to the procedures of the examples disclosed above.

Also, although the polyolefin-polyamide composition has been described in its filamentary ribbon textile-forming form, the composition also can be used to make a union dyed fabric having a non-woven fabric or film form of the union dyed, polyolefin-polyamide composition backing tufted with a polyamide or polyester fiber yarn and union dyed according to the invention.

The term fiber as used in describing the invention includes and is intended to include filaments of round, rectangular, oval, or other known cross-sectional forms, whether the fiber is in continuous or discontinuous, e.g. chopped, fibrous form. The term yarn likewise includes and is intended to include textured and non-textured yarns made of the above-described fibers.

TABLE 1.-DISPERSE DYESTUFFS Dyestnfl used, percent Ex. N o. Dyestufl name Color index number Face yarn o.w.g. Color rating 5 Latyl Yellow RC Disperse Yellow 8, 0.1. ENCRON Polyester 5 At or near No. 12690. union shade. 6 Latyl Yellow 4RL Disperse Yellow 23, .....do Do.

0.1. No. 26070. 7 Latyl Yellow YLW..--- Disperse Yellow 42, Blue Polyester .5 Do.

0.1. No. 10338. 8 Latyl Yellow 3G Disperse Yellow 54 ENCRON Polyester .5 Do. 9..- Latyl Orange NST Disperse Orange 25.- Blue 0" Polyester.. .5 Do. Disperse Orange 26.- .-do .5 Do. Disperse Orange 40 ENCRON Polyester .5 Do. Disperse Orange 41 do .5 Do. Disperse Red 55 ..do .5 Do. Disperse Bed 56. do .5 Do. Disperse Red 59 Blue "0 Polyexter .5 Do. Disperse Red 60- -.d Do. Disperse Red 65- ENCRON Polyester.-. .5 Do. Disperse Red 88- 5 Do. Dlsperse Violet 17. .....do 5 Do. Dlsperse Violet 18 Blue 0" Polyester 5 Do. Disperse Violet 26 do .5 Do. Disperse Violet 27 ..do 5 Do. Disperse Blue 27, 0.1. o.-. .5 Do.

No. 60767. Disperse Blue 59-. 6 Do. Disperse Blue 60.. 5 Do.

Disperse Blue 62-. 5 Do. Disperse Blue 63.. 5 Do. Disperse Blue 64.- 5 Do. Disperse Blue 65.- 5 Do. Disperse Brown 2. 5 Do. Disperse Violet 27-.. 5 Do. Disperse Violet 26-.. 5 Do. Disperse Yellow 23.. 5 Do. Disperse Red 65- 5 Do. Latyl Yellow 3G Disperse Yellow 54 -.do .5 Do.

1 The Colour Index, Textile Chemist and Colorist, Products-70, September 1969, vol. No. 20A, .lour. AATCC.

TABLE 2.ACID DYES'IUFFS Dyestufi used, Color index percent Ex. No. Dyestufi name number o.w.g. Color rating 86 Merpecyl Blue SW 180251 1 1 3 2 Nylon 6 2. 0 At union shade.

. 0. 62055. Kl Merpaeyl Blue SK Acid Blue 78, ...-.do 2. 0 Do.

0.1. No. 62105. 38 Merpaoyl Blue 26A Aegl Bl ge 40, .....do 2.0 Near union shede 0.1 62125. 39 Merpacyl Yellow AR Acid Orange 132 ..do.. 2.0 At union shade. 40 Merpacyl Yellow G. Acid Yellow 175.- 2. 0 Do. 41.. Merpacyl Yellow 4G- Acid Yellow 174.. 2. 0 Do. 42.. Merpacyl Yellow 8G. Yellow 2.0 Do. 43.. Merpaeyl Orange R... Acid Orange 128 2.0 Do. 44-... Merpacyl Red G--. Acid Red 337 2.0 D0. A5 Merpacyl Red L Acid Red 151, .-do 2.0 Do.

01. No. 26900. 48 Merpaeyl Red B Acid Red 266 --do 2.0 Do;

1 Du Ponts ANTRON Type 846.

I claim: a basic polyamide comprising the reaction product 1. A process for preparing a union dyed fabric, said process comprising of an aliphatic dicarboxylic acid for derivative thereof and a polyamine containing not more than two union dyeing in a dye bath selected from acid dye baths and disperse dye baths a synthetic fabric containing synthetic fibers selected from the group consisting of polyamide and polyester fibers in a fiber blend with fibers of a polyolefin composition,

said polyamide consisting of a long chain synthetic primary amino groups and one or more tertiary amino groups, wherein said basic polyamide is present in an amount sufiicient to provide 0.1 to 1.0% by weight of basic nitrogen in the composition and said basic polyamide has a crystallite melting point in the range 50-250? 0., and

polyamide having recurring amide groups said acid dye bath being used only with the polyamide fibers, and the disperse dye bath being used with both the polyamide and polyester fibers.

2. The process of claim 1 wherein the polyamide is hexamethylene adipamide.

3. The process of claim 1 wherein the polyester is polyethylene terephthalate.

4. The process of claim 1 wherein the polyolefin is selected from the group consisting of linear polyethylene, stereoregular poly-(4-methylpentene-1) and isotactic polypropylene.

5. The process of claim 1 wherein the polyamine consists of a mixture of methyl bis(3-aminopropyl) amine and hexamethylenediamine.

6. The process of claim 1 wherein the dye bath is an as an integral part of the polymer chain,

said polyester being a long chain synthetic polymer composed of at least 85% by weight of an ester of a dihydric alcohol and terephthalic acid and said composition comprising 80-99.5% by weight of a stereoregular polyolefin and 0.5 to 20% by weight of 11 acid dye bath and the synthetic fiber-forming substance is a polyamide.

7. The process of claim 1 wherein the dye bath is a disperse dye bath.

8. A union dyed tufted textile fabric comprising (a) a backing consisting of fibers of a polyolefin composition, said composition comprising 8099.5% by weight of a stereoregular polyolefin and 0.5 to 20% by weight of a basic polyamide comprising the reaction product of an aliphatic dicarboxylic acid for derivative thereof and a polyamine containing not more than two primary amino groups and one or more tertiary amino groups, wherein said basic polyamide is present in an amount suflicient to provide 0.1 to 1.0% by weight of basic nitrogen in the composition and said basic polyamide has a crystallite melting point in the range 50-250 C.,

(b) face yarn consisting of synthetic fibers selected from the group consisting of polyamide and polyester fibers, said polyamide consisting of a long chain synthetic polyamide having recurring amide groups as an integral part of the polymer chain, said polyester being along chain synthetic polymer composed of at least 85% by weight of an ester of a dihydric alcohol and terephthalate acid (c) a union shade of color in both said backing and face yarn provided from at least one synthetic dye selected from acid dyes and disperse dyes, wherein said acid dyes are used only with the polyamide face yarn, and the disperse dyes are used with both the polyamide and polyester face yarns.

9. The union dyed tufted fabric of claim 8 wherein the polyamide is hexamethylene adipamide.

10. The union dyed tufted fabric of claim 8 wherein the polyester is polyethylene terephthalate.

11. The union dyed tufted fabric of claim 8 wherein the polyolefin is selected from the group consisting of linear polyethylene, stereoregular poly-(4-methylpentene- 1) and isotactic polypropylene.

12. The union dyed tufted fabric of claim 8 wherein the polyamine consists of a mixture of methyl bis(3- aminopropyl) amine and hexamethylenediamine.

13. The union dyed tufted fabric of claim 8 wherein the polyolefin is isotactic polypropylene.

14. A union dyed textile fabric comprising (a) fibers of a polyolefin composition, said composition (b) synthetic fibers selected from the group consisting of polyamide and polyester fibers, said polyamide consisting of a long chain synthetic polyamide having recurring amide groups as an integral part of the polymer chain, said polyester being a long chain synthetic polymer composed of at least by weight of an ester of a dihydric alcohol and terephthalic acid (c) a union shade of color in both said composition and fibers provided from at least one synthetic dye selected from acid dyes and disperse dyes, wherein said acid dyes are used only with the polyamide fibers, and the disperse dyes are used with both the polyamide and polyester fibers.

References Cited UNITED STATES PATENTS 3,485,569 12/1969 Newby et a1. 821 B 3,433,853 3/1969 Earle et a1. 260-857 3,361,843 1/1968 Miller 260-857 3,439,999 4/1969 Miller 815 3,485,574 12/1969 Miller 8168 X OTHER REFERENCES Cuthbertson et al.: The Textile Manufacturer, September 1964, pp. 353-359.

DONALD LEVY, Primary Examiner US. Cl. X.R.

82l C; 57140 B; 161-62 

